Method of and apparatus for making veneered cellular concrete walls.



C. 0. ELLERT. METHOD 0F AND APPARATUS FOR MAKING VENEERED CELLULAR CONCRETE'WALLS.

APPLICATION FILED MAR. I0 |914. IIENEWED APR. 10,19I8.

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0.0. ELLEN. y METHOD 0F`AND.APPARATUS F06 MAKING VENEERED CELLULAR CONCRETE WALLS.

APPLICATION FILED MAR.' l0. l9l4. RENEWED APR. l0. 1918.

Patented Unt. 11,1918.,

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CHARLES O. ELLERT, OF BROOKLYN, NEW YORK.

METHOD OF' AND APPARATUS FOR MAKING VENEERED CELLULAR CONCRETE WALLS.

Specication of Letters Patent.

Patented Oct. 1L, M1218.

Application filed March 10', 1914,' Serial No. 823,808. Renewed April 10, 1918. Serial No. 227,825.

To all 'whom t may concern: Y

Be it known that I, CHARLES O. ELLERT, a citizen of the United States, and aresident of the city of New York, borough of Brooklyn, county of Kings, and State of New York, have invented new and useful Improvements in Methods of and Apparatus for Making Veneered Cellular Concrete Valls, of which the following is a specification.

This invention relates to a method of,

Nand apparatus for improving integrally formed concrete walls.

A building wall made bythemethod of, and apparatus herein described has alternate cellular and pilastered sections throughoutr the wall and is of greater strength than hollow walls heretofore constructed; also provides a veneering or facing on both the outer and inner surface of the improved cellular concrete wall; without in any man- .ner detracting in `strength and usage from that of an equal sized wall of solid reinforced concrete.

This invention will be understood by a reference to the accompanying drawings forming a part of the specification, in which similar reference characters refer to similar parts throughout the several views.

Figure I, is an elevation showing a portion of a veneered, cellular, pilastered, reinforced concrete building wall, and a mold as in relative operation; certain portions of the mold apparatus being removed to show a detail operation of the mold and the formation of the veneered, cellular concrete wall.

Fig. II, is a cross section on line 2 2, Fig. I, parts of mold apparatus being removed, and parts broken away to show detail operative relation of the mold apparatus and the formation of the veneered, cellular, pilastered concrete wall; the broken detail inside wall C, showing a preferred manner of securing mold panels, is better shown in Fig. III.

Fig. III, isan enlarged broken section of the cell forming means of the apparatus, and a portion. of side wall C; parts being broken away, showing preferred manner of positioning and alining inoldjpanels'in the building of the wall. p i

Fig IV, is a perspectiveof `a core holding means or core carrier forming part of `the pilaster and cell forming means used in connection with the formation of the cellular, .pilastered concrete wall.

Fig. V, is a central vertical section of one of the chambered perforated cores.

Figs. VI, VII, a bottom and top perspective, respectively of va chambered, perfol broken sections through the veneered, cellular, pilastered concrete wall, showing modiiications in construction, and showing variations in positioning the lining or veneering on both the outer and inner faces of the cellular, pilastered, re-inforced concrete wall.

A, indicates `a veneered, cellular, pilastered, reinforced concrete building wall in the course of construction, B, indicates a suitable mold, which includes in its construction, the side walls C and D, suitably constructed, which are positioned and alined by a detachable, longitudinal wall gage member 8.

A preferredtype of mold, is as shown,

`that will permit one of its side walls as C lcaused by the meeting edges of adjoining sectionsof said facing elements, to be coated or sealed by a coating or sealing and bonding material or layer L of plastic or like, applied to the rear faces of said facing ele- `ments,` to formsaiol plurality of facing ele- AV .Tlflents into one continuousandV impervious lining or veneering for the said concrete Wall; l j j The said sealingand bonding material or layer L, of plastic or like is applied to the facing elements, previous to the erection of side Wall C to a height corresponding to Y that of the side Wall D.

The sealing and bonding material, or

layer L of plastic is adapted to become set or hardened quite readily, and not only readily seals, and closes all joints and crevices of the said facingieleinents, but also greatly assists in positioning 'said facing elementsv by firmly bonding the said plurality of facing elements on their rear faces, into Aone continuous and imperviouslining or veneering; and also this sealing and bonding material or layer L .of plasticor like is applied to a suitable thickness' and adapted tobecoine an integral part of the cellular, pilastered concrete Wall. j

The sealing and .bondig material or .layer nL of plastic is preferably applied with a on its rear face to Wet orliquid plastic or concrete.

y, By the hereindescribed method ofb'uilding veneered, cellular, concrete Walls, one of .the side Walls ofthe mold, as D, is erected always to. .an advanced height beyond that 'of opposing side ivallnG. The plurality of facing elements are readily positionedad- Yjacent the. inner face of said side Wall D,

and a .sealing and bonding material or layer of plastic or like, is readily applied to the rear .faces ofsaid plurality o-f facing elements to form or construct a continuous and imperviouslining or veneering for said concrete Walls. The .outer faces of said plurality of facing elements, adjoining theinner face of said Wall D, need not have a seal- .:ing and bonding .material or layer applied to close the outer joints or crevices, because the sealing .and bonding L applied to the rear faces of said facing elements,` is sufficient to prevent Wetor liquid Vplastic from penetrating orleakingthrough the sealed and bonded lining or veneering adjacent the inner face of said side Wall of inoldm Any. crevicesor joints showing .on the outside of the facing orveneeiing, afteiremovalof said side ,WallD, maybe pointed hand with a troivel or by other suitable means- 'hemegeneous .Wall4 ,facing 0.1i veneer-ins in which a plurality of unconnected facing material or layer positioned intermediatethe said facing elements and the A,Wet plastic V poured' in the mold; in this manner not only are the individualy facing elements carried or supported by theset and hardened sealing @amending.material Orlayer Abut e better bonding engagement with Wet plastic is attained informing a veneered, cellular concretewall. ,j t a, ,er ,e ,n

` The horizontal broken sections through the veneered, cellular concrete Wall shown in Figs. XII, XIII, are approximately on a line of the horizontal meetingledgesofthe facing elements The Sealing anclbndrs. material or klayer L being shown extending longitudinally intermediate the cellular Acon crete ivalland thevvvall facing, completely einbeddingthe tile positioning means and presenting a continuous, sheet of bonding surface to the Wet plastic usedrtoforin the concrete Wall. In ,FigHILfor clearness` of drawing the holding means J are shojvn uncovered by thesealing and bonding material or layer, but as described, the sealing and bondingl material or layer L ris applied to a suitable thickness to form an impervious vintegral Wall .facing or ve1`ieering, and said Wall facing is in turn bonded to suitable plastic to form a veneered, cellular concrete W311- Y ,A a -Y a While suitable forms 4of, moldsinay be adapted to the purpose ofconstructing veneered, cellula-r lconcrete Walls, I prefer al type of side Wall of a mold suitable `for positioning a lining or veneering adjacentits innner face, as shown at D, the standards 1,

are provided with aligned openings or slots 2, 3, and l, andare eachpositionedfand alined, andv detachably secured to ajlongitudinal Wall gage member 8, in a manner so each standard is independently and removably secured, independent Aof any adjoining standard; Asuperposedf removable spacing members 9, having. slots orf perforations 10, 11a, to register With coacting slots orperforationsin said standards, are

positioned adjacent the inner faces ofco-acting staiidards, and suitable ,mold boards or .u panels 12, 12a, having [lioldin'gfmeans 14C `in recesses 13L ator neai' 'thefeiids of Vsaid ,nioldboaiids'orpanelslQ, 12a, arev placed adjacent ac'oacting superposed removable spac- 125 ing member '9, 9a,*iii..ay mannerjtopermit ,Y .said holding iineansglfigtc register With said registeringslots oiopenings' 11a, in said coacting removable spacingfmemberslfl, 49E* removable fastening ineans preferably clamp- 13o l With said holding `means 14?, in the mo d panels 12, 12a.

The removal of the fastening means 15, 15a, permits the removal of spacing members 9, 9a, and mold panels 12, 12a, and removing the fastening means 8b, from the Wall gage member l8, together With the removal of tie rods 5, permits the removal of the standards 1, from the finishedwall.

Suitable facing elements I,^of slate, terra cotta, or other` material, are detachably positioned adjacent the inner face of said side wall D, and removable threaded vbolts or like means S having threaded ends R to engage With .threaded nuts K, are passed through or between the said mold panels 12, 12a, forming the side Wall D, and be- Y tween the edges of the facing elements, or

` able cells openingout through the inner face through notches placed in the edges of said facing elements if desired, and engage with a suitable holding or anchoring means J, of suitable longitudinal angle iron members having suitable holes `or openings to receive the threaded ends R of the fastening'means S, and of suicient length to engage a number of the facing elements, adjacent the rear faces of said facing elements I.

The said facing elements I, When positioned, present crevices or joints at the meeting edges of adjoining facing elements, and as described a sealing and bonding material or layer L, of plastic `or `like is applied With a brush or any suitable means to the rear facesrof said facing elements I, to a suitable thickness to seal and close all the said crevices and joints, and prefererably ing or veneering fora concrete Wall.'

The saidside Wall C,jopposing the said side Wall D, is preferably of la collapsible construction, similar to that ofside wall D, and is provided With a collapsible apparatus or means to be carried or positioned adjacent the inner `face Aof said side Wall C, for forming cellular, concrete Walls with suitof said cellularvvalls, similar to a-honeycomb` typev of Wall construction and for forming if desired, suitable pilasteredV sections, preferably intermediate and Aalternating with the said cellular sections of said concrete Walls; the said side Walls C, is

erected in Vdiminished height to that of side Wall D,'eXcept `at the finish of construction of the cellular, pilastered Wall, when said side Walls C and D are of equal height if l desired.

As shown in FigfI, A, indicates ave- -n-eered, cellular concrete Wall; the cellular sections of theV Wall although shown in sinlateral extending cells Gr, opens into a vertical or flue like recess F,in the inner face of the cellular Wall.

Intermediate and alternating with the cellular sections of the Wall, are reinforced pilasters E, provided with, if desired smaller open cells G; the inner lining or veneering H, is of suitable material and is preferably positioned and secured to suitable 'anchor means N, of suitable material embedded or secured in suchiof the smaller cells G', as desired, leaving open those cells G', not used for this purpose. If desired, suitable anchoring means O, Fig. XI, may be suitably positioned in some of the larger lateral extending cells G, and the inner lining or veneering I-I, suitably secured by suitable screws or nails I-I, with an intermdiate moisture proof lining M, of suitable materi-al, between the face of the `Wall `and the inner lining or veneering H.

The inner lining or veneering Isl, is adapted to form a closure means, referring to Figs. XII and XIII, for closing the vertical recesses F, in the inner face of the cellular Wall in a manner to provide a vertical flue like means in the inner face of the cellular wall, and the cells G, 1in the cellular Wall open into the said vertical flue like recesses F, in the inner face'of the said Wall.

The said open cells Gaare adapted to eX- tend laterally through the inner face ofthe cellular Wall, though the body of the said Wall, to a point in the interior of the Wall near the outer surface thereof, to leave a suficient thickness of solid concrete vvall to support the outer lining or veneering I, as heretofore described.

The said collapsible appa Iatus or means, positioned adjacent the inner face of said side Wall C, for forming cellular pilastered concrete walls, comprises, preferably, re-

`movable adju-stable longitudinal core carof said core carrier; a suitable holding means 21, preferably, a slotted plate is securedwithin the larger slot or opening 19, and is adapted to rest on shoulders provided Within said larger slot or opening 19;

`said slotted plate or holding means 21, is secured to said shoulders by Y suitable screws 22, or like means.V y Y Q The slots or opening's21, of the slotted holding plate 21, opens into 4the smallerrecess or opening 20, inthe opposite face of said core carrier 18. 'Ihe said core carriers means.

the -set concrete.

1n the bottomends of saidcores 23, is provlded afchambered recess or OpeningQ, and

rmovable securing means preferably clamping bolts 31, engaging suitable points,pref

lerably, at or near the top and bottom ends of said core carriers 18, and pass through the side wall C, notches being provided 1n aside `wall C, to receive said securing means 31, and secured by a suitable nut 32, or like Removable cell forming cores of a suitable construction, are provided, and are positioned adjacent the inner face of a side wall of a mold, intermediate the standards, or adjacent the mold panels, andare removably secured by suitable fastening means passing through said side wall and engaging said cores. I prefer cell forming cores 23, as shown in' Fig. V, provided with a chambered recess or opening 25, in the top end of said cores and a chambered recess or opening 26, in the bottom end of said cores, these chambered recesses or openings are connected by a longitudinal, perforation or tube 24, opening into each of said recesses or openings 25, and 26; a holding means 27, or a modied form of holding plate similar to that of 21, in the core carrier 18, is provided in the top end of said cores 23, and extending across the chambered recess 25, and over the said perforation or tube 24:, to provide a slidable, adjustable engagement with a suitable removable securing means 31, passingthrough or between' the units or members comprising said side walls, if desired, suitable notches or like means may be provided in said side Wall to receive said securing means 31. The said securing means 31, are adapted to pass through the slotted plate 21, in Acore carriers 18, and engage said holding means 27, in the top end of said cores 23; a slotted holding plate similar to that of 21, in core carrier 18, may be used in place of the said holding means 27, in cores 23, but

it is desired that said holding means 27, or

like means inthe top en'd of cores 23, be arranged to protect the opening of the perforation or tubev 24,-, provided in said cores 23, as said tube 24, is provided to permit air to pass into the cells G, as the said cores 23, are being removed or withdrawn from the set concrete, thereby reducing the suction caused by the removalof said cores from said concrete.

The closure means 30, preferably a plug of suitable material, lnay be left adhered to into which one end of the said tube 24;, opens,

.the said;,op`eningj26pis adapted to receive a clcsuremeans .30, of4 Suitable material t0 :elose saidv --erfcraton or tube 24:, against :entranceoH *plastic inte sai-d tube 291;; a

`suitablejaeket or inolosing envelop' or like means 29, preferablyof paper, may inclose the said cores 23, toprevent plastic from adjacent each said core carrier 18, and adapted to laterally extend from said core carriers 18, partly across the mold space.

`Suitable removable securing means, as 31, 41, are adapted to be positioned between the mold panels 12, o-n notches or like openings along the meeting edges oflsaid mold panels `to engage the said cores and to permit the said mold panels to have edges.

A modification, in positioningv said cores tight meeting 23, lis readily seen referring to Fig. III; suitable removable securing means 311, engage the said cores 23, in a manner similar to the securinglmeans 31, but the threaded nuts 35, or like means engages the slotted plate 21, positioned in core carrier 18, said nut 35, is positioned within said larger recess or opening 19, and below the plane of the face of the core carrier.

The cell forming cores 23a, for forming the smaller cells G', are preferably posi-y tioned parallel to the larger cores 23, and intermediate the core carriers 18, and adjacent the mold panels 12; referring to Fig.

1, the removable securing means 31, engag- `ranging members or auxiliary core carriers 36, are provided and positioned adjacent the said slotted openings 39, in amanner-to lie adjacent, and cover the said slotted opening 39, and extend or rangehorizontally to adjoining core carriers 3S, adjacent said side wall of mold to cover equivalent slotted openings 39, in said adjoiningoore carriers 38, in the same manner; said --horizotlta'lly ranging members or auxiliary @Orecar'refs 36, are provided with suitable openings or Vperfoiations to permit removable rsecuring -means 31, or `other suitable means, to pass through said openings in said auxiliary core nesaasv carriers 36, and engage with adjacent removable cores; said auxiliarycore carriers 36, areadapted to be positioned intermediate and preferably, alternating with suitable mold boards or panels 37. In this modification, the side wall of mold may be suitably constructed, and including the auxiliary core carriers 36, may be entirely dismantled and removed, leaving, if desired, the said cores in the newly formed wall, for removal at a later time from the set concrete.

In Figs. XI, XII, and XIII, I show modifications in construction of veneered, cellular concrete walls, in Fig. XI, the laterallyV extending cells Gr, in vertical series are carried out and open through the inner face of the wall A, and flush with the pilastered sections E, and in Figs. iXII, XIII, the laterally extending cells G, open into the flue like recesses F, in the -inner face of said wall` A. The recesses F may be'- closed by the inner lining H to form isolated air passages, or may be connected by suitable air spaces or passages F', or in any desired manner.

I have herein shown a method of, and apparatus for making veneered, cellular concrete walls, wherein are described improvements producing an improved hollow wall of a type suitable for dwellings.

While I have shown and described the preferred embodiment of my invention, it will be understood that I do not wish to be limited to the precise construction herein set forth, since various changes in the form and minor details may be resorted to without departing from the principle of, or sacrificing any of the advantages of this invention.

Having thus described the invention, what I claim as new and desire to secure by Letters Patent is 1. A method of building veneered, concrete walls, which consists in setting up a plurality of unconnected facing elements spaced from a mold element, applying a coat of plastic bonding material to the rear faces of said facing elements to form an integral, impervious veneer, and depositing plastic concrete between said veneer and said mold element.

2. A method of building veneered, concrete walls, which consists in detachably securing a plurality of facing elements to one inner face of a wall mold, applying a coat of plastic bonding material to the rear faces of said facing elements to form an integral, impervious veneer, and depositing plastic concrete between said veneer and the opposite mold face.

3. A method of building veneered, cellular concrete walls, which consists in setting up a plurality of unconnected facing elements spaced from a mold element, positioning a plurality of laterally extending cores upon said mold element, applying a coat Of plastic bonding material to the rear faces of said facing elements to form an integral, impervious veneer, and depositing plastic concrete between said veneer and said mold element and around said cores.

4e. A method of building veneered, cellular concrete walls, which consists in detachably securing a plurality of facing elements to one-inner face of a wall mold,

, applying` coat of plastic bonding material to the rear faces of said facing elements to form an integral, impervious veneer, positioning a plurality of laterally extending cores upon the opposite inner face of said mold, and depositing plastic concrete between said veneer and said opposite mold face and around said cores.

5. A method of building veneered, cellular concrete walls, which consists in detachably securing a plurality of facin elements to one inner face of a wall mo d, applying a coat of plastic bonding material to the rear faces of said facing elements to form an integral, impervious veneer, positioning a plurality of laterally extending cores upon the opposite inner face of said mold, depositing plastic concrete between said veneer and said opposite mold face and around said cores, detaching said first mold element from said facing elements, and withdrawing said second mold element and its attached cores from the wall.

6. A mold for veneered concrete walls, comprising spaced mold walls, means connecting said walls, one of said walls adapted to detachably engage an integral, impervious veneer, and cell forming means upon the opposing mold wall, said means including a plurality of elements adapted to pass through said opposing mold wall and detachably engage a plurality of cylindrical cores to extend partly across the mold space.

7 A mold for veneered concrete walls, comprising spaced mold walls, means connecting said walls, one of said walls adapted to engage a detachable impervious veneer, and a plurality of cylindrical cores detachably clamped to the opposing mold wall to extend partly across the mold space.

8. A mold for veneered concrete walls, comprising spaced mold walls, means connecting said walls, one of said walls adapted to engage a detachable impervious veneer, a plurality of removable securing means positioned upon and passing through spaced notches or openings provided to extend through or between mold panels positioned in the opposing mold wall, and a plurality of cylindrical cores engaging said securing means and detachably clamped to the said opposing mold wall to extend partly across the mold space.

9. A mold for veneered concrete walls, comprising spaced mold walls, means con- Copies of this patent maybe obtained for necting said walls, one of said walls adapted to engage a detachable integral, impervious veneer, the opposite mold Wall provided with a 4plurality of spaced notches or openn ings` adapted to lpass through Said opposite mold WalLanda cell forming means upon said opposite moldwall, said means includingapluralty of elements adapted to pass throughsaid spaced notches or openings and detachably7 .engage a plurality of `cylindrical-cores to extend partly across the mold space.v n

V10. A mold for .veneered concrete Walls, comprising spaced inold Walls, means connecting said Walls, one of said Walls adapted to detachably engage an integral, impervio usyeneer, and a cellorming means upon the opposing mold Wall, said means including a plurality of elements adapted to pass engage a plurality ofcylindricallcores to` register adjacent the. exposed 4faces of said. core carriers to extend `partly across the mold space.

VIn testimony. name in Jthe presence of two Witnesses.

CHARLES O. ELLERT.

.Witnessesz HOWARD E. Pn'r'rrr, JOSEPH HOYM.

ve cents each, by addressing the Commissioner of Patents, l

Washington, ID. C.

whereof7 I have signed my 

